Series-Stacked EV Battery Cells With Sealed Polymer Frame Compartments
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Solution Overview
Problem
The assembly and manufacturing of series-stacked battery cells for electric vehicles are expensive and prone to failure due to electrolyte sealing issues and mechanical stress, which can lead to battery cell failure under vibrations or movement.
Innovation Solution
A battery module design featuring polymer frames with separate electrolyte compartments, allowing for easy assembly and stable connection of battery cells in series, using polymer frames that can be attached to bipolar current collectors and separators, and filled with liquid or gel electrolyte, providing a robust and sealed compartment structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional series-stacked battery cells are assembled using molds and resin, then series connection is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The battery pack is divided into multiple independent battery cells, each with its own sealed electrolyte compartment. This segmentation allows each cell to be manufactured and assembled independently, then stacked in series without requiring complex mold and resin processes, thereby reducing manufacturing cost while maintaining series connection stability.
Solution Approach 2:
The bipolar current collector serves dual functions: as an electrical conductor for series connection and as a structural component integrating multiple cells. By merging these functions into a single component, the design eliminates the need for separate molds and resin, reducing manufacturing complexity while achieving reliable series connection.
2Power
If battery cells are stacked in series to increase voltage, then voltage output increases, but sealing of electrolyte becomes more difficult and prone to failure
Solution Approach 1:
A polymer membrane is used to seal the electrolyte compartment. This flexible thin film provides effective sealing while accommodating thermal expansion and mechanical stress, preventing electrolyte leakage even when multiple cells are stacked in series, thus maintaining reliability while achieving higher voltage.
3Power
If battery cells are stacked in series, then voltage increases, but mechanical stress and vibrations can lead to cell failure
Solution Approach 1:
The polymer membrane sealing provides flexibility that allows the battery structure to accommodate mechanical stress and vibrations without rigid failure points. This flexible sealing maintains structural integrity under mechanical load while enabling series stacking for higher voltage.
Solution Approach 2:
The battery structure combines different materials (polymer membrane, bipolar current collector, electrolyte) with complementary properties. The polymer provides flexibility and sealing, while the bipolar current collector provides structural strength, creating a composite structure that resists mechanical stress and vibrations while maintaining series connection for high voltage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design facilitates cost-effective and stable assembly of battery modules with improved mechanical resilience, reducing the risk of cell failure and allowing for efficient series connection, while tolerating small imperfections and mechanical stress, thus enhancing the reliability of electric vehicle batteries.
Implementation Method 1
electrolyte filling the compartment for one of the plurality of battery cells
Implementation Method 2
a separator separating the cathode and the anode
Data Source
AI summary
A battery module includes a plurality of battery cells connected in series, each battery cell having a cathode, an anode, and a separator separating the cathode and the anode, and a bipolar current collector; a plurality of polymer frames, each having a window to receive part of the one of the plurality of battery cells; two of the plurality of polymer frames defining a compartment; and electrolyte filling the compartment for one of the plurality of battery cells. A method is also provided.